US20120211474A1 - Laser lap welding method - Google Patents

Laser lap welding method Download PDF

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Publication number
US20120211474A1
US20120211474A1 US13/372,601 US201213372601A US2012211474A1 US 20120211474 A1 US20120211474 A1 US 20120211474A1 US 201213372601 A US201213372601 A US 201213372601A US 2012211474 A1 US2012211474 A1 US 2012211474A1
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US
United States
Prior art keywords
laser
laser beam
welding
lap welding
irradiation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/372,601
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English (en)
Inventor
Kazuhiro Hayashimoto
Yuta Fujinuma
Tsukasa HAGIHARA
Yoshitaka Sanuki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Suzuki Motor Corp
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Suzuki Motor Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Suzuki Motor Corp filed Critical Suzuki Motor Corp
Assigned to SUZUKI MOTOR CORPORATION reassignment SUZUKI MOTOR CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJINUMA, YUTA, HAGIHARA, TSUKASA, HAYASHIMOTO, KAZUHIRO, SANUKI, YOSHITAKA
Publication of US20120211474A1 publication Critical patent/US20120211474A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/28—Seam welding of curved planar seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0665—Shaping the laser beam, e.g. by masks or multi-focusing by beam condensation on the workpiece, e.g. for focusing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/244—Overlap seam welding

Definitions

  • the present invention relates to a laser lap welding method, and more particularly to a laser lap welding method which improves a hole, an indentation, and the like, that are caused at a welding terminating end.
  • a laser welding method in which a laser beam is irradiated onto a workpiece to heat and melt a material of the irradiated portion by the light energy of the laser beam, has an advantage in that high speed welding can be performed in a non-contact manner, but has a problem in that a hole and an indentation are caused at a welding terminating end.
  • this problem has become one of the factors that limit the use of the laser welding method to only some automobile parts and prevents the laser welding method from being used for the vehicle body welding process in which strict management of performance and quality about airtightness, water leakage, and the like, is required.
  • the perforation and indentation which are caused in a laser welding terminating end, are caused by molten metal supplied to the welding terminating end eventually becoming insufficient due to a phenomenon in which the molten metal flows in the direction opposite to the welding advancing direction.
  • a method which is referred to as “ramping” or “fade down” and in which the laser output is controlled to be gradually reduced toward the welding terminating end.
  • JP2008-264793A As another measure against the above-described problems, a method is disclosed in JP2008-264793A in which the laser irradiation diameter is increased at the welding terminating end by defocusing the laser beam.
  • the laser beam is stopped and defocused to increase the laser irradiation diameter
  • new defects such as burn-through of the upper steel sheet and the spattering of molten metal, may be induced instead of an improvement in the hole and indentation.
  • An object of the present invention is to provide a laser lap welding method which can improve the hole and indentation at the welding terminating end while avoiding an increase in the space and the cycle time that are required to secure the welding length.
  • a laser lap welding method includes: performing lap welding ( 11 ; 21 ) by irradiating a laser beam (La) on a plurality of overlapped workpieces ( 1 , 2 ); and then irradiating, after a very short interruption time period of the laser irradiation, a defocused laser beam (Lc) on a terminating end ( 12 ; 22 ) of the lap welding.
  • the non-molten metal around the molten metal can be melted without the molten metal being scattered, and the recessed section at the welding terminating end is filled and flattened by the newly produced molten metal flowing into the recessed section.
  • the welding length be reduced to prevent the formation of a hole and an indentation at the welding terminating end, and that the weld bead be extended to avoid the reduction in the welding length.
  • the focus adjustment of the laser can be performed during the interruption of the laser irradiation, and since the interruption time period is very short (about 30 to 50 milliseconds in a practical example), the interruption of laser irradiation hardly affects the welding cycle time.
  • the welding method according to the present invention include: performing lap welding ( 11 ; 21 ) by irradiating the laser beam (La) on a plurality of overlapped workpieces ( 1 , 2 ); then interrupting the laser irradiation for a very short time period and performing, during the interruption time period, movement (Lb) of the laser optical axis from the terminating end (e) of the lap welding to the side of the starting end of the lap welding; and irradiating the defocused laser beam (Lc) from the position (cs) to which the laser optical axis is moved, on the terminating end (e) of the lap welding.
  • a form can also be considered in which the defocused laser beam is irradiated while being moved in the opposite direction from the terminating end to the starting end.
  • the defocused laser beam is then irradiated from the position to which the laser optical axis is moved, to the terminating end in the same direction as the direction at the time of the lap welding.
  • the laser optical axis can be moved during the interruption time period of laser irradiation, and hence the cycle time is not affected.
  • the irradiation (Lc) of the defocused laser beam is performed at a higher speed than the speed of laser irradiation (La) at the time of lap welding.
  • the defocus amount of the laser beam can be reduced as compared with the case in which the energy density of the laser beam is reduced only by the defocusing, and that the time required for the irradiation of the defocused laser beam can also be reduced.
  • the interruption time period of the laser irradiation be 0.025 to 0.25 seconds.
  • the interruption time period of the laser irradiation is less than 0.025 seconds, the cooling of the molten metal at the terminating end of the lap welding becomes insufficient. Thereby, a burn-through and an indentation are easily caused at the time of irradiation of the defocused laser beam, so that welding quality cannot be maintained.
  • the interruption time period of the laser irradiation is too long, the cycle time is increased, so that the productivity is lowered. Therefore, it is advantageous for the interruption time period of the laser irradiation to be set to be as short as possible in the range in which stable welding quality can be obtained.
  • the laser lap welding method according to the present invention it is possible to reliably prevent the formation of a hole and an indentation at the welding terminating end while avoiding an increase in the space required for securing the welding length and an increase in the cycle time.
  • the laser lap welding method according to the present invention is advantageous to improve the quality of laser lap welding.
  • FIG. 1 includes FIG. 1(A) which is a plan view showing a laser scan in a laser lap welding method according to a first embodiment of the present invention, FIG. 1(B) which is a plan view showing a bead shape, FIG. 1(C) which is a graph showing the laser output and the defocus amount, FIG. 1(D) which is a graph showing the laser scan speed, FIG. 1(E) which is a sectional side view of a lap-welded portion, and FIG. 1(F) which is a cross-sectional view of a lap welding terminating end;
  • FIG. 2 includes FIG. 2(A) which is a plan view showing a weld bead before irradiation of a defocused laser beam in a laser lap welding method according to a second embodiment of the present invention, FIG. 2(B) which is a cross-sectional view along the line B-B in FIG. 2(A) , FIG. 2(C) which is a plan view showing a weld bead after irradiation of the defocused laser beam, and FIG. 2(D) which is a cross-sectional view along the line B-B in FIG. 2(C) ;
  • FIG. 3 is a graph showing a relationship between the defocus amount and the indentation depth in each of the cases in which the gap between workpieces is set to (a) 0.2 mm, (b) 0.1 mm, and (c) 0.05 mm;
  • FIG. 4 is a graph showing a relationship between the laser irradiation interruption time and the indentation depth
  • FIG. 5 is a graph showing a relationship between the defocus amount, the laser beam diameter, and the bead width at the lap welding terminating end;
  • FIG. 6 includes FIG. 6(A) which is a sectional side view showing a conventional laser lap welding method, FIG. 6(B) which is a plan view showing the conventional laser lap welding method, FIG. 6(C) which is a graph showing the laser output, and FIG. 6(D) which is a sectional side view showing another conventional laser lap welding method.
  • FIG. 1 shows a case in which laser lap welding 10 according to a first embodiment is performed on two steel sheets 1 and 2 (galvanized steel sheets), so as to form a linear welding portion having a predetermined length.
  • the two steel sheets 1 and 2 are overlapped via, for example, embossments (protrusions, not shown) press formed in advance on one side (or both sides) of the steel plates, and thereby the two steel sheets 1 and 2 are held with jigs (not shown), such as clamps, in the state in which a tiny gap g for discharging zinc vapor is formed between the two steel sheets 1 and 2 .
  • the gap g may be formed by spacers, or the like, instead of forming the embossments.
  • the two steel sheets 1 and 2 may be directly overlapped without forming the gap g.
  • the focus control of the laser is performed to set the defocus amount to Dc, so that, at predetermined laser output Pc and scanning speed Vc, defocused laser irradiation Lc is performed so as to overlap with the weld bead 11 from the point cs to which the laser optical axis is moved, to the terminating end e.
  • a recessed section 11 b (transient indentation) is left at the terminating end e of the weld bead 11 as shown by the solid line in FIG. 1(F) .
  • the laser irradiation Lc is performed in such a manner that the energy density is reduced and the spot diameter is increased by the defocusing as shown by the broken line in FIG. 1(F) .
  • the non-molten metal around the recessed section 11 b is melted and flows into the recessed section 11 b , as a result of which the recessed section 11 b is filled and thereby the welding terminating end 12 is flattened.
  • the defocus amount Dc is not limited in particular, but it is preferred to set the defocus amount Dc such that, as shown in the graph of FIG. 5 , a bead width Bc, which is about 1.5 to 2 times the width Ba of the weld bead 11 , is obtained at the welding terminating end 12 .
  • the length (cs ⁇ e) of the defocused laser irradiation Lc is not limited in particular, but needs to be set to the length of about 2 times the width (Ba) of the weld bead 11 , and is preferably set to 3 times or more the width (Ba) of the weld bead 11 .
  • the substantial welding length Wa becomes slightly shorter than the length of the weld bead 11 formed on the surface of the welded portion, but the depth of the recessed section 11 b temporarily formed at the terminating end e of the weld bead 11 is reduced.
  • the reduction in the depth of the recessed section 11 b is advantageous for flattening the welding terminating end 12 by the defocused laser irradiation Lc.
  • FIG. 2 includes FIG. 2(A) which is a plan view showing a weld bead 21 before defocused laser irradiation in laser lap welding 20 according to a second embodiment of the present invention, FIG. 2(B) which is a cross-sectional view along the line B-B in FIG. 2(A) , FIG. 2(C) which is a plan view showing weld beads 21 and 22 after the defocused laser irradiation, and FIG. 2(D) which is a cross-sectional view along the line B-B in FIG. 2(C) .
  • the laser lap welding 20 shows an embodiment which forms a circular weld bead (C-shaped weld bead) having an opened portion, and which is particularly suitable for laser welding (unit welding) as an alternative to spot welding in an automotive vehicle body welding process.
  • the welding procedure of the laser lap welding 20 is the same as that of the laser lap welding 10 according to the above-described first embodiment except that the laser scan is performed in a partially opened ring shape.
  • the reason why a laser scan is not performed in a closed ring shape, but is performed in a partially opened ring shape, is that the laser scan is performed so that the discharge path of the zinc vapor in the space surrounded by bead 20 is secured between the starting end s and the terminating end e of the laser scan performed to again approach the starting end s.
  • a recessed section 21 b (transient indentation) is formed at the terminating end e of the weld bead 21 at the time of terminating the laser irradiation La.
  • the defocused laser irradiation Lc in which the spot diameter is increased, is performed as shown in FIG. 2(A) and FIG. 2(B) , the non-molten metal around the terminating end e is melted and flows into the recessed section 11 b , and thereby the welding terminating end section 22 is flattened so that the excellent weld bead 20 is obtained.
  • the welding process is performed intermittently at suitable intervals by using, as a unit welding process, the linear laser welding 10 according to the above-described first embodiment or the circular laser welding 20 according to the above-described second embodiment.
  • the laser lap welding La of another welding spot adjacent to the welding spot is performed, and then the defocused laser irradiation Lc is performed to the previous welding spot.
  • an optical fiber laser oscillator (having a maximum output: 7 kW, a diameter of transmission fiber: 0.2 mm) manufactured by IPG photonics company, and a scanner head (having a processing focal diameter in the focused state: 0.6 mm) manufactured by HIGHYAG laser technology company were used.
  • the scanning speeds Vc was set to 10 m/min close to the scanning speed Va, and when the defocus amount Dc was set in a small range of 30 mm or less, a burn-through was caused. It is inferred that this is because the substantial power density was not sufficiently reduced, and hence the discharge of zinc vapor and the thermal diffusion were insufficient. Therefore, when a small gap g is set between the two steel sheets 1 and 2 , the substantial power density in the laser irradiation Lc may be sufficiently reduced by increasing the defocus amount Dc (to 35 mm or more), or by increasing the scanning speed Vc (to the double speed or more of the scanning speed Va).
  • the case is described in which the movement Lb of the laser optical axis is performed to the side of the starting end during the interruption time period of laser irradiation, and in which the defocused laser irradiation is then performed from the point cs to which the laser optical axis is moved, to the terminating end e.
  • the defocused laser irradiation can also be performed from the terminating end e to the side of the starting end s. In this case, it is necessary that the interruption time period of laser irradiation be set to be slightly longer than the interruption time period in the above-described embodiments.
  • the case is described in which the two steel sheets are overlapped and laser-welded.
  • the laser lap welding method according to the present invention can also be applied to a workpiece having another form, and can also be applied to the case in which three or more steel sheets are overlapped and laser-welded.
  • the cases in which the weld bead has a linear shape and a circular shape (circular arc shape) are shown in the above-described embodiments, but the laser lap welding method according to the present invention can be applied to an arbitrary shape of the weld beam other than these shapes of the weld bead.

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Laser Beam Processing (AREA)
US13/372,601 2011-02-22 2012-02-14 Laser lap welding method Abandoned US20120211474A1 (en)

Applications Claiming Priority (2)

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JP2011-036174 2011-02-22
JP2011036174A JP2012170989A (ja) 2011-02-22 2011-02-22 レーザ重ね溶接方法

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US20150102639A1 (en) * 2013-10-16 2015-04-16 Toyota Jidosha Kabushiki Kaisha Vehicle-body member joining structure and vehicle-body structure
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US20160311154A1 (en) * 2015-04-23 2016-10-27 Cooler Master Co., Ltd. Method of manufacturing rotor
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US10668565B2 (en) * 2015-02-09 2020-06-02 Spi Lasers Uk Limited Apparatus and method for overlap laser welding
US20200376592A1 (en) * 2018-02-16 2020-12-03 Panasonic Intellectual Property Management Co., Ltd. Laser welding device and laser welding method
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WO2018179032A1 (ja) * 2017-03-27 2018-10-04 三菱電機株式会社 レーザー溶接方法
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